Factory Futures

Summary

This was such a good episode.

I sat down with Odell Lavigne to talk about leadership in some of the toughest environments imaginable, and this conversation was packed with practical lessons, strong opinions, and real-world experience.

Odell shares lessons from leading through fires, explosions, Covid, layoffs, and toxic workplace cultures. We discuss why he believes a leader's number one responsibility is the physical and psychological safety of their people, why great leaders focus on prevention rather than firefighting, and how to influence change even when you don't have authority.

We also explore organisational structure, resource utilisation, and what it really takes to build a high-performing organisation that can grow without burning people out.

Whether you're a site leader, engineering manager, reliability professional, or aspiring leader, I think you'll get a lot out of this one.

Chapters

00:00 Introduction and Odell's Career Journey
03:38 How Sales Shaped My Leadership Style
07:52 Why Safety Is a Leader's Number One Responsibility
09:02 What Psychological Safety Actually Looks Like at Work
13:52 Crisis Leadership and the Power of Prevention Over Reaction
19:35 The Tesla Rainstorm Story: Turning Chaos Into a System
27:12 Moving Organisations from Immature to Best-in-Class
32:04 How to Get People Bought Into Change
35:04 The Blind Management Story: Winning Over Critics and Building Better Systems
47:03 Why Managers Fail to Become Leaders

49:56 Quick Fire Round Begins
50:19 The Fastest Way to Destroy Trust
50:37 What Strong Leadership Looks Like
50:52 The Most Dangerous Phrases in Business
51:58 How to Influence Culture Without Authority
53:19 What Separates Good Leaders from Great Leaders
54:29 Advice for Leader

Key quotes

1. "I don't mind fighting fires. I'm just never fighting the same fire twice."
2. "People don't dislike change. They dislike the negative consequences of poorly executed change."
3. "Leadership is influence."
4. "The critics are the first people I want to talk to."
5. "Stay calm. People don't need you to have all the answers. They need you to lead them to the answers."

Links

Odell on Linkedin : https://www.linkedin.com/in/odell-lavigne-lssbb/

Keywords

Leadership, Manufacturing, Reliability, Maintenance, Operations, Site Leadership, Safety Culture, Psychological Safety, Crisis Leadership, Organisational Design, Continuous Improvement, Change Management, Industrial Leadership, Team Development, Operational Excellence.

Links

The book : https://gerardwood.com.au/product/only-tradies-improve-reliability/

Gerard's profile : https://www.linkedin.com/in/gerard-wood-146a3212/

Summary

In this episode, I sat down with Gerard Wood, author of Only Tradies Improve Reliability, for one of the most honest conversations we’ve had on the podcast about maintenance culture, leadership, and what really drives reliability outcomes.

Gerard shares why he believes reliability is not primarily a systems problem, but a trades culture problem. We unpack why good tradies can still produce poor outcomes, the difference between “don’t know”, “don’t care”, and “don’t see”, and the simple routines high-performing sites use to make quality visible every day.

What I enjoyed most about this conversation is that it cuts through a lot of the complexity our industry often creates. Gerard brings the discussion back to pride in work, ownership, feedback, and craftsmanship and why those things matter more than most people realise.

If you work in maintenance, reliability, or operations leadership, I think this episode will genuinely make you reflect on the culture at your site and what actually drives long-term reliability improvement.

Chapters

00:00 Introduction to Gerard Wood's Journey

02:58 The Importance of Culture in Reliability

05:28 The Uncomfortable Truth About Systems and Culture

08:49 Understanding the 'Don't Know, Don't Care, Don't See' Phenomenon

16:08 Making Quality Visible for Improvement

20:32 Identifying and Addressing Equipment Issues

24:39 The Impact of Ownership and Pride in Work

27:25 Creating a Culture of Openness and Learning

32:17 The Future of Trades and Technology

35:14 Quickfire Insights on Reliability and Culture

Keywords

Reliability, Maintenance Culture, Mining, Continuous Improvement, Leadership, Quality Work, Reliability Engineering, Organizational Culture, Safety, AI in Maintenance

Summary

In this episode, I sit down with Edwin Rodriguez who shares insights on equipment reliability, the impact of organizational culture, and the critical relationship between sales, service, and operations in manufacturing. Discover practical strategies to reduce downtime, foster ownership, and improve communication across teams.

Links

Edwin's Linkedin : https://www.linkedin.com/in/edwin-rodriguez-568902204/

Connect with Chesterton : https://chesterton.com/

Chapters

00:30 Introduction and Background of Edwin Rodriguez

02:37 Understanding Equipment Reliability Challenges

04:48 The Reality of Unplanned Downtime

07:14 Bridging the Gap Between Operations and Reliability

09:48 The Importance of Training and Communication

12:21 Fostering Ownership and Accountability in Operators

14:57 Cultural Shifts for Improved Reliability

17:44 The Role of Meetings in Enhancing Collaboration

21:58 Building Collaborative Teams

22:50 Understanding the Disconnect Between Sales and Service

23:40 Cultivating Relationships for Reliability

31:37 The Importance of Sales and Service Collaboration

35:25 Leadership in Reliability and Team Dynamics

Sound Bites

"Ownership starts with culture and leadership"

"A reactive mindset leads to broken equipment"

"Teamwork is the foundation of reliability"

Key Topics

Impact of organizational culture on equipment reliability

The importance of communication and collaboration across teams

Root cause analysis and proactive maintenance strategies

Keywords

equipment reliability, downtime reduction, organizational culture, maintenance, sales and service collaboration, root cause analysis, proactive mindset, leadership in reliability

Summary

In this episode, I sat down with Jim Wilson, Maintenance Manager at Hiland Dairy Foods, Lean Six Sigma Black Belt, and Industrial Electrical Instructor, to talk about what reliability really means inside a modern manufacturing site.

We started by reframing reliability as a risk reduction function, not just maintenance. Jim shared why unplanned downtime isn’t just about repair costs, but about product safety, audit exposure, lost production, and even brand damage. We also got into the connection between PM discipline, documentation, and how sites perform under regulatory pressure.

From there, we dug into why so many reliability programs fail. We talked about the gap between having a CMMS and actually using it properly, the hidden cost of poor troubleshooting, and what it takes to build real accountability and follow-through inside a maintenance team.

We wrapped up with a really practical discussion on developing skilled technicians. Jim explained why troubleshooting is about following a diagnostic sequence rather than memorising fixes, and how training, mentorship, and structured systems can lift both performance and retention.

This one is a grounded, practical conversation for anyone leading maintenance or reliability and trying to move from reactive firefighting to a more structured, high-performing operation.

Chapters

00:00 Introduction to Jim Wilson's Journey

07:01 Understanding Reliability as Risk Management

11:25 Shifting from Reactive to Structured Reliability Culture

17:24 The Importance of PM Discipline and Audit Outcomes

21:43 Why Reliability Programs Fail and CMMS Utilization

25:02 Effective Parts Control and Inventory Management

26:42 Building Relationships in Maintenance Management

27:17 Common CMMS Mistakes and Best Practices

29:48 The Hidden Costs of Poor Troubleshooting

32:48 Understanding the Cost of Downtime

34:05 Effective Troubleshooting Techniques

37:43 Developing Skilled Technicians

44:26 The Importance of Mentorship and Certification

Key Topics

1. Reliability as risk management, not just maintenance
2. Why reliability programs fail and how to succeed
3. The importance of PM discipline and documentation
4. The role of culture in reliability and safety
5. Troubleshooting skills and knowledge transfer
6. The impact of unplanned downtime on brand and safety
7. Using CMMS effectively for maintenance and audits
8. Developing skilled technicians through mentorship and training

Sound Bites

"Unplanned downtime can damage brand reputation."

"Know everything about your CMMS and use it fully."

"Upskilling technicians creates lasting change."

Links

Linkedin : https://www.linkedin.com/in/jimewilson/

Keywords

Reliability, Maintenance, CMMS, Troubleshooting, Continuous Improvement, Dairy Industry, Risk Management, PM Discipline, Culture Change

Summary

In this episode, I sat down with Loïc Estier to talk about a problem almost every factory has, but rarely talks about properly.

We explored how so much of the knowledge needed to run a plant at its best is locked in people’s heads, and what happens when that knowledge isn’t available at the moment you need it.

Loïc shared some great stories that really bring this to life, and we dug into why traditional approaches like documentation and knowledge bases don’t work the way we think they should.

We also talked about what’s changing now with AI, and how capturing real, day-to-day communication might be the key to finally solving this problem.

It’s a practical, thought-provoking conversation that I think will make a lot of people reflect on how knowledge actually flows through their site.

Links

Linkedin : https://www.linkedin.com/in/loic-e/

Website : https://rossops.com/

Chapters

00:00 Introduction to Knowledge Capture in Manufacturing

03:07 Loïc Estier's Journey and Insights

05:46 The Human Element in Manufacturing

08:39 The Challenge of Data Utilization

11:10 The Importance of Experience-Based Knowledge

14:04 Real-World Examples of Knowledge Gaps

16:26 The Need for Effective Knowledge Management Solutions

19:16 Traditional Knowledge Bases vs. Modern Solutions

21:59 Leveraging AI for Knowledge Capture

24:31 Conclusion and Future Directions

24:46 Understanding Structured vs. Unstructured Data

30:00 The Future of AI in Manufacturing

35:19 Shift Communication and Knowledge Management

39:34 Navigating AI's Role in Operational Efficiency

42:34 Focusing on Improvement, Not Firefighting

Sound Bites

"Data is just facts without context."

"Most knowledge is in people's heads."

"Ross is the expert in every factory."

Keywords

Manufacturing, Knowledge Management, AI, RossOps, Operational Data, Industry 4.0, Digital Transformation, Factory Efficiency, Shift Handover, Data Capture

Follow Shane:

• Linkedin : https://www.linkedin.com/in/shane-scriven/
• Website : https://www.sas-am.com/

Summary:

AI is everywhere right now, but what does it actually look like on the factory floor?

In this episode, we unpack three practical areas shaping the next wave of AI in manufacturing. We explore how AI-powered benchmarking can help sites truly understand performance, where low-cost AI can deliver value without massive investment, and what sovereign and edge AI mean in simple terms for real operations.

This is a grounded conversation focused on making AI more understandable, more accessible, and ultimately more useful for reliability, maintenance, and site leaders.

Chapters

00:00 Introduction to AI in Manufacturing

06:47 The Second Wave of AI

11:26 Understanding AI-Powered Benchmarking

16:10 Identifying Gaps with AI

20:42 Automating Maintenance Processes

24:14 Implementing Low-Cost AI Solutions

26:58 Common Pitfalls in AI Projects

32:04 Defining Low-Cost AI

35:39 Starting with AI as a Reliability Manager

37:42 Rapid Fire Round: Insights and Myths

Sound Bites

• "AI is not self-aware or conscious"
• "Avoid ignoring data insights"
• "Autonomous assets will make decisions"

In this episode, JP sits down with Marcelo Fariello, Plant Manager at Mars, to explore a powerful idea: reliability isn’t just a maintenance function — it’s a leadership system.

Marcelo shares lessons from his journey across digital transformation, operational excellence, and plant leadership, including his time at Danone and now leading a major Mars site in Australia.

They unpack why many reliability programs stall when they sit solely within maintenance, and what changes when operators take true ownership of their equipment. Marcelo explains how shifting to site-wide accountability can unlock performance gains that tools alone never will.

The conversation also dives into the reality of digital reliability tools — why so many initiatives fail, what actually works, and the cultural foundations required before technology can deliver value.

Finally, Marcelo breaks down how high-performing sites treat reliability as a leadership discipline, focusing on behaviours, mindset, and breaking down silos between production and maintenance.

If you’re a maintenance leader, reliability engineer, or site manager, this episode will challenge how you think about ownership, digital transformation, and what it really takes to build a reliable operation.

Chapters

00:00 Introduction to Marcelo's Journey

02:51 Reframing Reliability and Maintenance

03:33 The Importance of Ownership in Operations

08:44 Strategies for Cultural Change

11:11 Defining Operator Ownership

13:11 The Role of KPIs in High-Performance Teams

15:26 Effective KPIs for Reliability

18:21 The Power of Measurement

26:03 Digital Transformation and Its Challenges

32:04 Leadership as a System

36:09 Hard Truths in Reliability Management

Sound Bites

"Silos create a superhero mentality."

"Ownership drives pride and performance."

"KPIs should motivate, not just measure."

Key Topics

Holistic leadership in reliability and operations

Operator ownership and cultural change

Role of KPIs and data in continuous improvement

Episode Summary

In this episode of our predictive maintenance series, we take a step back and tackle something many sites skip: defining the problem before jumping into PdM.

Before selecting assets, installing sensors, or launching a pilot, maintenance and reliability teams need to be clear on what they’re actually trying to improve. Is the goal to reduce reactive work? Extend inspection intervals? Increase MTBF on key asset classes? Without alignment on the problem, PdM pilots often drift, expectations collide, and even good results can be misunderstood.

We talk through what a strong PdM problem statement looks like, share examples with clear metrics, and discuss how teams can align around success before any technology is introduced. We also address a common concern many sites raise: “We don’t even have good data.” The reality is that every site has signals to start from, even if they’re messy.

If you’re considering predictive maintenance or planning a pilot, this episode will help you start in the right place: clarity before technology.

Chapters

00:00 Introduction to Predictive Maintenance

01:57 Defining the Right Problem

08:19 Crafting a Clear Problem Statement

28:51 Data Challenges in Predictive Maintenance

34:09 Conclusion and Next Steps

Sound Bites

"Start with a problem, not just more data."

"Measure the impact over a realistic timeframe."

"Align your team and get buy-in early."

Keywords

predictive maintenance, problem statement, asset management, reliability, maintenance strategy, data quality, pilot projects, business outcomes

Laith's Linkedin : https://www.linkedin.com/in/laithalfaqih/

Connect with Stantec : https://www.stantec.com/en

Summary

Many organisations invest in asset management programs, new systems, and predictive tools, yet reliability performance often doesn’t improve as expected. Why? In this episode, JP sits down with Laith Alfaqih, Senior Principal and Asset Management Lead at Stantec, to explore organizational readiness. They discuss why asset management should be treated as a management system, not a toolkit, the most common readiness gaps across industries, and a practical framework leaders can use to assess whether their organisation is truly ready to make asset management stick.

Chapters

00:30 Introduction and Context Setting

04:00 Understanding Organizational Readiness

06:40 Defining Asset Management and Its Importance

11:23 Challenges in Asset Management Initiatives

17:12 Leadership's Role in Asset Management

22:41 Reframing Asset Management as a Management System

25:12 Holistic Asset Management Approach

27:04 Challenges in Data Collection and Management

33:25 Organizational Readiness Blueprint

42:23 Assessing Organizational Readiness

46:12 Leadership Actions for Improvement

Sound Bites

"Preventing issues starts with good data and standards"

"Trust your people, empower them, and provide resources"

"Think with the end in mind for success"

Key Topics

Organizational readiness definition and importance

Common reasons for asset management project failures

Leadership's role in asset management success

Data quality and standards in asset management

Creating a culture of continuous improvement

Links

Simon's Linkedin : https://www.linkedin.com/in/yourmaintenancecoach/

Simon's Website :

https://yourmaintenancecoach.com/

Last Year's Episode:

https://open.spotify.com/episode/1u6P5ulYwL5Si7VEdLggRj?si=OEk27vxMSaCWXAtwO882jA

Summary

In this episode, Simon Murray revisits the evolving trends in maintenance and reliability for 2025, sharing insights from recent conferences, community building, and technological advancements like AI. Discover how organizations are shifting their focus towards system efficiency, store management, and the importance of community networking to stay ahead in maintenance practices.

Chapters

05:40 Reflections on 2025: Changes and Trends

08:12 Community and Networking in Maintenance

11:02 Economic Pressures and Budgeting in Maintenance

13:44 The Importance of Maintenance Operations Partnership

16:31 Justifying Maintenance Needs to Leadership

28:05 Building Trust in Maintenance Operations

29:21 The Importance of Systems Efficiency

32:53 Workshops for Process Improvement

35:24 Revamping Stores Management

42:34 The Challenge of Preventive Maintenance Reviews

46:07 The Impact of AI on Maintenance

48:53 Setting Priorities for the Next 90 Days

Key Topics

Community and networking in maintenance

Recognition for reliability from leadership

Systems efficiency and digital transformation

Stores improvement and inventory management

PM review practices and challenges

Sound Bites

• "Most maintenance teams have had this awakening"
• "We've almost reached the limit of what we trust Google"
• "AI will have the biggest impact in the next three years"

Keywords

maintenance trends, reliability, AI in maintenance, community networking, asset management, system efficiency, stores improvement, PM review, industry 2025